KTM 85 SX 2003 User manual

OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2003
BEDIENUNGSANLEITUNG
Art.Nr. 3.210.48 1/2003
85 SX

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1
Please insert the serial numbers of your motorcycle in the boxes below
PLEASE INSERT BELOW THE SERIES NUMBERS OF THE MOTORCYCLE
FRAME NUMBER
ENGINE NUMBER
STAMP
OF DEA-
LER
IMPORTANT
PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR
YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUAL
CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT
WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE
MOTORCYCLE PROPERLY.
IN THE INTEREST OF EVERYBODY INVOLVED, WE URGE YOU TO PAY PARTI-
CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS
FOLLOWS:
 WARNING 
IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE
AND LIMB.
! CAUTION !
IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE
MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC
SAFETY.
Chassis number
Engine number
Stamp of dealer
KTM S PORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATIONS , COLORS ,
MATERIALS , SERVICES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT
PRIOR NOTICE AND WITHOUT GIVING REASONS
, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM
WITH OTHERS
. I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCE -
MENT . I NTHE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .

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2
Introduction
Now you own a modern motorcycle that you and your youngster will certainly enjoy,
provided that you service and maintain it properly. This manual contains important
information on the operation and maintenance of your new KTM motorcycle. It went
to press describing your model’s latest state of development. Nevertheless, the descrip-
tions may deviate slightly from the current design as our motorcycles are permanently
improved.The Owner's Manual is an integral part of the motorcycle and must be han-
ded over to the new owner when the motorcycle is sold.
We expressly point out that work marked with an asterisk in the chapter "Mainten-
ance work on the chassis and engine" must be performed by a KTM workshop. If
maintenance work should become necessary during a competition, it must be perfor-
med by a trained mechanic.
Please strictly observe the prescribed running-in periods and inspection and mainten-
ance intervals. Compliance with these instructions will significantly prolong the life of
your motorcycle.
Be sure to have the maintenance work carried out by a KTM workshop to avoid losing
your right to claim under the warranty.
For the safety of your child, only use spare parts and accessories approved by KTM.
KTM shall not assume any liability for other products or consequential damage resul-
ting from the use of such products.
When special needs arise, please contact a KTM dealer, who will seek the assistance of
the KTM importer if necessary.
PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends
on the efforts made by the parents to ensure that the motorcycle is kept in good wor-
king order and only used on safe terrains. Nevertheless, driving the motorcycle, like
driving any other vehicle, involves a potential risk. Therefore, please make sure that all
fundamental precautions are taken. Please also read the „INFORMATION ON SAFE
DRIVING FOR PARENTS“ on page 4.
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we
certainly hope that you and your youngsters will enjoy it to the full. However, this
enjoyable outdoor activity can cause environmental problems or lead to conflicts with
other people. Responsible use of the motorcycle will prevent such problems and con-
flicts. You can contribute to securing the future of motorcycling by making sure that
you and your youngsters only use the motorcycle within the limits established by the
applicable laws, making environmental protection one of your top priorities and never
violating other people’s rights.
In this spirit, we hope that you and your youngsters will always safely enjoy your
motorcycle!
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments: 1 spare parts manual chassis & engine
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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IMPORTANT WARRANTY AND
GUARANTEE INFORMATIONE
KTM mini-sports motorcycles are designed and constructed to resist the usual
wear and tear of normal use in competitions.
The motorcycles comply with the regulations and categories currently in
effect with the leading international motorcycle associations.
Observance of the service, maintenance and tuning instructions for the
engine and chassis specified in the Owner's Manual is a prerequisite for fault-
less operation and the avoidance of premature wear. An improperly tuned
chassis can lead to damage and breakage of the chassis components (see
chapter on checking the basic chassis setting).
The service work specified in the "Lubrication and Maintenance Schedule"
must be performed by a KTM workshop and recorded in the service manual
otherwise claims under the warranty shall become void.
The fuels and lubricants specified in the Owner's Manual or automotive
fluids with equivalent specifications must be used in accordance with the
maintenance schedule.
No claims can be filed under the warranty for damage or consequential
damage caused by manipulations or conversions to the motorcycle.
The use of the motorcycle under extreme conditions, e.g. on extremely
muddy and wet terrain, can lead to higher than average wear on compo-
nents such as the drive train or the brakes. In this case it may become neces-
sary to service or replace wear parts before the service limit specified in the
maintenance schedule has been reached.
In accordance with the international quality management
ISO 9001 standard, KTM uses quality assurance processes
that lead to the highest possible product quality.

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The 85 SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on
public roads.
The vehicle dimensions and components are designed for children from 10 to 15 years of age with a maxi-
mum weight of 75 kg (33,98 lb).
–Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye
protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear
protective gear yourself whenever riding a motorcycle!
–Adjust the clutch lever and hand brake lever to match your child's hand size (with gloves).
–Adjust the basic setting of the foot brake pedal to your child's seating position.
–Before your youngster takes his or her first ride, explain how each of the controls works and check if your
youngster has understood what you explained. We recommend to review the entire owner’s manual with
your youngster item by item, paying particular attention to the specially marked warnings and pointing out
the danger of injury.
–Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to
shifting of the rider’s weight, etc.
–Before starting the motorcycle for the first time check whether the basic fork and shock absorber settings
are suitable for your child's weight (see chapter on checking the basic chassis setting)
–Before using the motorcycle you should always check all components for proper operation
(see maintenance schedule). Have your youngster perform these technical checks himself / herself as well.
–Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to your
youngster and not the other way around.
–Your youngster must understand that all instructions he or she receives from you or any other supervising
adult must be followed.
–Your child must be physically ready to ride a motorcycle. This means that he or she must at least be able to
ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your youngster
should be strong enough to pick up the motorcycle after a fall.
–Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to
improve his / her riding skills. Do not even consider letting your youngster participate in a race before his /
her physical condition, riding skills and motivation have sufficiently developed.
–Explain to your youngster that he / she should always adjust his / her riding speed to the local conditions as
well as to his / her own riding skills and that excessive speed can cause falls and severe injuries. Always
keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether. The riding
speed must be reduced, in particular, on unknown terrain.
–Never let your youngster ride the motorcycle without supervision. An adult should always be present.
–The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.
–When you go for a ride, somebody at home should always know where you are going and when you will
be back. This makes it easier to send you help, should problems occur.
IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING

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TABLE OF CONTENTS
Page
IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE
DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .6
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Plugin- Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of fork . . . . . . . . . . . . . . . . . . . .8
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .8
Damping action during compression of shock absorber .9
Rebound damping function of the shock absorber . . . . .9
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Instructions for the first ride . . . . . . . . . . . . . . . . . . . . .10
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .11
What you should check before each start . . . . . . . . . . .11
Starting when the engine is cold . . . . . . . . . . . . . . . . . .12
Starting when the engine is warm . . . . . . . . . . . . . . . .12
What to do when the engine is “flooded“ . . . . . . . . . .12
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .14
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .16
Checking and adjusting the steering head bearing . . . . .16
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . .17
Page
Cleaning the dust sleeves of the telescopic fork . . . . . .17
How to change the handlebar position . . . . . . . . . . . . .17
Changing the spring preloading of the shock absorber .18
Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . .18
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .18
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .18
General information about KTM disc brakes . . . . . . . . .19
Adjusting free travel of the hand brake lever . . . . . . . .19
Checking brake fluid level - front brake . . . . . . . . . . . .20
Refilling front brake fluid reservoir . . . . . . . . . . . . . . . . .20
Checking the front brake pads . . . . . . . . . . . . . . . . . . .20
Replacing the front brake pades . . . . . . . . . . . . . . . . . .21
Changing basic position of the brake pedal . . . . . . . . . .21
Checking the rear brake fluid level . . . . . . . . . . . . . . . .22
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .22
Checking rear brake pads . . . . . . . . . . . . . . . . . . . . . . .22
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .22
Dismounting and mounting the front wheel . . . . . . . . .23
Dismounting and mounting the rear wheel . . . . . . . . .24
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .24
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Changing the original position of the clutch lever . . . . .26
Checking the oil level of the hydraulic clutch . . . . . . . .26
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .26
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Checking coolant level . . . . . . . . . . . . . . . . . . . . . . . . .27
Refilling/Bleeding the cooling system . . . . . . . . . . . . . .27
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . . .27
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .28
Draining the float chamber of the carburetor . . . . . . . .29
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
TECHNICAL SPECIFICATIONS – CHASSIS 85 SX 2003 . .33
TECHNICAL SPECIFICATIONS - ENGINE 85 SX 2003 . . .34

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Chassis number
The chassis number is stamped on the right side of the steering head tube.
Enter this number in the field on page no 1.
Engine number
The engine number is stamped into the engine housing underneath the
carburetor. Enter this number in the field on page no 1.
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The adju-
sting screw Ais used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
Hand brake lever
The hand brake lever 2is mounted on the handle bars on the right and
actuates the front wheel brake.The adjusting screw Bis used to change the
original position of the hand brake lever (see maintenance work on chassis
and engine).
Short circuit button
The short circuit button 3turns off the engine. When pressing this button,
the ignition circuit is short-circuited.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1
2
A
B
3

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Filler cap
To open it: turn filler cap counter-clockwise.
To close it: put filler cap back on and tighten it by turning it clockwise.
Install tank breather hose 1without kinks.
Fuel tap
OFF In this position the fuel tap is closed. No fuel can flow to the carburetor.
ON When the motorcycle is running the grip is must be in the ON
position to enable fuel to flow to the carburetor. The tank will
drain completely in this position.
Choke
The choke button 2is located on the left side of the carburetor. Pulling the
choke button 2all the way out opens a bore in the carburetor through
which the engine can take in additional fuel, thus achieving the "rich" fuel
air mixture needed for cold starting.
Pushing the choke button back in closes the bore in the carburetor.
Shift lever
The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral, or the idle speed, is located bet-
ween first and second gear.
2,3,4,5,6
1
N
1
OFF ON
2

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8
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part
can be swivelled.
Foot brake pedal
The foot brake pedal is located in front of the right foot rest. Its basic posi-
tion can be adjusted to your seat position (see maintenance work).
Plugin- Stand
The plug-in stand 1included in the scope of supply can be plugged into
the left side of the bike at the end of the swinging fork.
Compression damping of fork
Hydraulic compression damping determines the reaction when the fork is
compressed. The degree of compression can be adjusted with adjusting
screws at the bottom of the fork legs.Remove the protecting cap.
Turn the knob 2clockwise to increase damping, turn it counterclockwise to
reduce damping during compression.
STANDARD ADJUSTMENT
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
Typ White Power 0518Y733...............20 clicks
Rebound damping of fork
Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the adjusting screw 3(REB), the degree of damping of
the rebound can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during rebounding.
STANDARD ADJUSTMENT
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
Typ White Power 0518Y733...............20 clicks
1
2
2
33

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9
Damping action during compression of shock absorber
The shock absorber on the models can synchronize the compression
damping in the low and high-speed range separately (Dual Compression
Control).
Low and high speed refers to the movement of the shock absorber during
compression and not to the speed of the motorcycle.
The low and high-speed technology overlaps.
The low-speed setting is primarily for slow to normal shock absorber
compression rates.The high-speed setting is effective at fast compression
rates.Turning in a clockwise direction will increase the damping, turning
counterclockwise will decrease the damping.
STANDARD LOW-SPEED SETTING:
–Turn the adjusting screw 1to the limit in a clockwise direction using a
screwdriver .
–Unscrew the respective number of clicks for the specific type of shock
absorber in a counterclockwise direction.
Typ White Power 1518Y703...............17 clicks
STANDARD HIGH-SPEED SETTING:
–Turn the adjusting screw 2to the limit in a clockwise direction using a
box wrench.
–Unscrew the respective number of turns for the specific type of shock
absorber in a counterclockwise direction.
Typ White Power 1518Y703 ...............2 turns
 WARNING 
THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION
NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY
MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
NEVER UNSCREW THE BLACK SCREW 3CONNECTION (24MM).
Rebound damping function of the shock absorber
The damping effect of the rebound damping mechanism can be adjusted by
levels by means of the setting wheel 4. Turn the setting wheel clockwise
(in) to increase and counterclockwise (out) to reduce the damping effect.
Typ White Power 1518Y703 ...............26 clicks
 WARNING 
–NEVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST
RIDES.
–D
ONOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM
MAINTENANCE WORK YOURSELF. DANGER OF INJURY!
4
1
2
3

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10
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE
 WARNING 
–HAVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER
HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE PROTECTION,
CHEST, BACK, ARM AND LEG PROTECTORS, GLOVES AND BOOTS. TO
SET A GOOD EXAMPLE, BE SURE TO WEAR PROTECTIVE GEAR YOURSELF
WHENEVER RIDING A MOTORCYCLE!
–O
NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.
–THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.
–Y
OUR YOUNGSTER'SDRIVING SPEED SHOULD ALWAYS BE ADJUSTED TO
HIS/HER DRIVING SKILLS AS WELL AS TO THE TERRAIN.
–YOUR YOUNGSTER SHOULD NEVER BE ALLOWED TO RIDE THE
MOTORCYCLE WITHOUT SUPERVISION.
–R
EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.
WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,
YOU WILL BE PRACTICALLY BLIND.
–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
 WARNING 
–SX MODELS ARE DESIGNED FOR ONE PERSON ONLY. PASSENGERS ARE
NOT ALLOWED.
–T
HESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY
STANDARDS ESTABLISHED BY THE LAW. THEREFORE, THEY ARE NOT
PERMITTED ON PUBLIC ROADS.
–A
LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCES-
SIVE NOISE.
Instructions for the first ride
–Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
–Before your youngster takes his or her first ride, explain how
each of the controls works and check if your youngster has
understood what you explained. We recommend to review
the entire owner’s manual with your youngster item by
item, paying particular attention to the specially marked
warnings and pointing out the danger of injury.
–Adjust the clutch lever, hand lever and foot brake pedal so
your child can operate them easily!
–To prevent injury, teach your youngster the basic riding
skills on soft ground, e.g. on a meadow or in the garden. Be
sure that there is room enough to maneuver, and that no
other riders are close.
–To ensure that your youngster gets the feel of the hand
brake, have your youngster operate the hand brake while
you push the motorcycle. Do not start the engine before
your youngster has learned to apply hand brake with appro-
priate pressure.
–To familiarize your youngster with the operation of the
hand brake let him or her practice to operate the hand
brake while you are pushing the motorcycle. Do not start
the engine before he or she is thoroughly familiar with the
use of the hand brake.
–Initially, your youngster should ride back and forth between
two persons who help the young rider to stop the motorcy-
cle. However, you should also teach your youngster how to
stop the motorcycle himself/herself.
–To improve his/her riding skills, your youngster should prac-
tise riding the motorcycle standing on the footpegs or to
riding at the slowest possible speed. Additionally, you can
arrange a series of obstacles and have your youngster drive
around them, etc.
–Pay attention to the running-in procedure.
Running in
–Even very precisely machined sections of engine compo-
nents have rougher surfaces than components which have
been sliding across one another for quite some time. There-
fore, every engine needs to be broken in. For this reason,
during its first 30 minutes the engine must not be revved up
to its performance limits.
–Apply low but changing loads for running-in.
–DO NOT DRIVE AT FULL LOAD FOR THE FIRST 30 MINU-
TES!

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11
DRIVING INSTRUCTIONS
What you should check before each start
When you start off, the motorcycle must be in a perfect technical condition.
For safety reasons, you should make it a habit to perform an overall check
of your motorcycle before each start.
The following checks should be performed:
1 CHECK TRANSMISSION OIL LEVEL.
A lack of gear oil leads to premature wear and finally results in destruc-
tion of the gear wheels.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the filler cap,
check that the tank venting hose is free of kinks.
3 CHAIN
A loose chain was fall off the chain wheels; an extremely worn chain
may tear, and insufficient lubrication may result in unnecessary wear of
the chain and chain wheels.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must be replaced.
Also check the air pressure. Insufficient tread and incorrect air pressure
deteriorate the driving performance.
5 BRAKES
Check the correct functioning of the braking system. Verify that there is
sufficient brake fluid in the reservoir. The reservoirs have been designed
in such a way that brake fluid does not need to be refilled even when the
brake pads are worn. If the level of brake fluid falls below the minimum
value, this indicates a leak in the braking system or completely worn out
brake pads. Always have the brake system checked by a KTM workshop
to avoid brake failure.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at the hand brake lever and foot brake lever.
 WARNING 
IFTHE RESISTANCE IN THE HAND BRAKE LEVER FEELS “SPONGY” (TOO MUCH PLAY),
THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM.
DON’TLET YOUR CHILD RIDE THE MOTORCYCLE ANYMORE WITHOUT FIRST HAVING
THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.

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12
Starting when the engine is cold
1 Open fuel tap 1.
2 Put the gear in neutral
3Activate the cold-starting aid (choke)2.
4 Leave throttle closed and kick down the kickstarter vigorously all the
way.
 WARNING 
–TOAVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR STRONG BIKERS
BOOTS!YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK IF YOU
DO NOT KICK HART ENOUGH.
–DONOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
! CAUTION !
DONOT RIDE YOUR MOTORCYCLE AT FULL LOAD AND DO NOT REV UP THE ENGINE
WHEN COLD. SINCE THE PISTON WARMS UP AND EXPANDS FASTER THAN THE WATER
COOLED CYLINDER, THIS MIGHT CAUSE ENGINE DAMAGE. ALWAYS LET ENGINE IDLE UNTIL
WARM OR DRIVE IT WARM AT LOW R.P.M. SPEEDS.
Starting when the engine is warm
1 Open fuel tap
2 Put the gear in neutral
3 Leave throttle closed and kick down kickstarter vigorously all the way.
What to do when the engine is “flooded“
1 Close fuel tap
2 Start engine with full throttle. If necessary, unscrew spark plug and dry
it.
3 Once the engine is running, open fuel tap again.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly release the clutch
lever and accelerate at the same time.
 WARNING 
ALWAYS REMOVE THE PLUG-IN 3STAND BEFORE YOUR CHILD RIDES THE MOTORCYCLE.
Shifting/Riding
You are now in first gear, referred to as the drive or uphill gear. Depending
on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Turn
down the throttle, at the same time pull clutch lever in and shift to the next
higher gear. Let clutch lever go again and open the throttle. If you turned
on the choke, make sure you turn it off again as soon as engine is warm.
When shifting down, use the brakes if necessary and turn down at the same
time. Pull clutch lever and shift down to the next lower gear. Let the clutch
lever go slowly and open throttle or shift down again.
 WARNING 
–AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS THOROUGHLY
BEFORE USING IT AGAIN.
–A
TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DONOT ADJUST THE HAND-
LEBAR, IT WILL LOSE STABILITY.
1
2
3

ENGLISH
13
! CAUTION !
–DRIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF
THE ENGINE. WERECOMMEND TO WARM THE ENGINE UP AT A
MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO
FULL LOAD.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
ALOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES.
INADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL.
–IFTHE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL
TRAVEL, THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO
ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS
MIXED IN THE FUEL.
–I
NTHE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTORCY-
CLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR
CHILD SHOULD STOP IMMEDIATELY, TURN THE ENGINE OFF, AND
CONTACT AN AUTHORIZED KTM DEALER.
Braking
Turn off the gas and apply the hand and foot brakes at the
same time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
 WARNING 
–I
N CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES
THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS,
HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE
BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN.
–D
IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS.
–W
HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER
AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEA-
KER THE BREAKING EFFECT. INEXTREME CASES, THE ENTIRE BRAKING
SYSTEM CAN FAIL.
Stopping
Brake motorcycle and shift gears to idling. To switch off the
engine, depress short circuit switch until the engine stops.
Close fuel tap.
 WARNING 
MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DONOT TOUCH ANY OF
THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO
PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BUR-
NED.
! CAUTION !
–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.
–T
HE PLUG-IN STAND IS DESIGNED TO HOLD THE WEIGHT OF THE
MOTORCYCLE ONLY. BYSITTING ON THE MOTORCYCLE, YOUR CHILD
WILL PUT ADDITIONAL WEIGHT ON THE PLUG-IN STAND, POSSIBLY
CAUSING THE PLUG-IN STAND OR SWINGING FORK TO BE DAMAGED
OR THE MOTORCYCLE TO FALL DOWN.
Refueling, fuel
Oil (high-grade two-stroke engine oil; i.e. Motorex Cross
Power 2T) must be mixed with the fuel (ROZ 95) at a mixing
ratio of 1:40.
 WARNING 
GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION
SHOULD BE USED WHEN HANDLING GASOLINE. NEVER REFUEL THE
MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS
SWITCH OFF THE ENGINE BEFORE REFUELING. BECAREFUL NOT TO SPILL
GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IFGASOLINE IS SWALLOWED OR SPLASHED IN
THE EYES, SEEK A DOCTOR’SADVICE IMMEDIATELY.
! CAUTION !
–ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-
GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN
CAUSE ENGINE FAILURE.
–O
NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL
(MOTOREX CROSS POWER 2T).
–N
OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE
PISTON. WHEN USING TOO MUCH OIL, THE ENGINE MAY START SMO-
KING AND FOUL THE SPARK PLUG.
–F
UEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT fill
the tank to the top. (see fig.)
40 mm

ENGLISH
14
PERIODIC MAINTENANCE SCHEDULE
after
20 hours
or
2000 kilometers
1st service
after 10 hours
or
1000 kilometers
after
4000 kilometer
or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S ERVICE I NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM !
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!
A clean motorcycle can be checked more quickly which saves money!
Check gear box oil level ●
Change gear box oil ●●
Check spark plugs, adjust distance between electrodes ●●
Renew spark plugs ●
Check the carburetor connection boot for cracks and leaks ●
Check idle speed setting ●●
Check that vent hoses are not damaged or bent ●●
Check cooling system for leaks, check quantity of antifreeze ●●
Check exhaust system for leaks and fitment ●
Check cables for damage, smooth operation, bends; adjust and lubricate ●●
Check oil level of the clutch master cylinder ●●●
Clean air filter and filter box ●
Check electric wires for damage and bends ●
Check function of electric systems ( emergency OFF switch or button) ●●
Check brake fluid level, lining thickness, brake lining ●●
Check brake lines for damage and leaks ●●
Check/adjust smooth operation and free travel of handbrake/foot brake lever ●●
Check tightness of brake system screws ●●
Check shock absorber and fork for leaks and function ●●
Clean dust bellows ●
Bleed fork legs ●
Check swing arm bearings ●
Check/adjust steering head bearings ●●
Check tightness of all chassis screws (triple clamps, fork leg axle passage ●●
axle nuts and screws, swing arm bearings, shock absorber)
Check spoke tension and rim joint ●
Check tires and air pressure ●●
Check chain, rear sprockets and chain guides for wear, fitment and tension ●●
Lubricate chain ●●
Check clearance of wheel bearings ●●
IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER
Check function of exhaust control ●
Complete maintenance of shock absorber ●
Complete maintenance of fork ●
Clean and grease steering head bearings and gasket elements ●
Clean and adjust carburetor ●
Replace glass fibre- yarn filling of the exhaust main silencer ●
Treat electric contacts and switches with contact grease ●
Change hydraulic clutch fluid ●
Change break fluid ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURETOR
ENGINE
85 SX
at least
once a year
every 2 years
or 20000 km

ENGLISH
15
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Check gear box oil level ●
Check brake fluid level ●
Check brake pads for wear ●
Lubricate and adjust cables and nipples ●
Bleed fork legs regulary ●
Remove and clean dust bellows regularly ●
Clean and lubricate chain, check tension and adjust if necessary ●●
Clean air filter and filter box ●
Check tires for pressure and wear ●
Check cooling liquid level ●
Check fuel lines for leaks ●
Empty and clean float chamber ●
Check all control elements for smooth operation ●
Check brake performance ●●
Treat blank metal parts (with the exception of brake and exhaust systems) ●
with wax-based anti corrosion agent
Check tightness of screws, nuts and hose clamps regularly ●
For cross- country use Once a year After every cleaning
Before each start
RECOMMENDED INSPECTION OF THE 85 SX ENGINE
USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)
Check the reed-type intake valve for wear ●●●●●●
Check the clutch shoes for wear ●●●●●●
Check the length of the clutch springs ●●●●●●
Check the cylinder and piston for wear ●●●●●●
Check the exhaust control for proper functioning and smooth running ●●●●●●
Check the eccentricity of the crankshaft journal ●●●●●●
Check the radial clearance of the conrod bearings ●●●
Check the radial clearance of the piston pin main bearing ●●●
Check the crankshaft main bearing for wear ●●●
Replace the crankshaft bearings and conrod bearings ●●●
Check the entire transmission including roller and bearings for wear ●●●
30
hours
45
hours
60
hours
90
hours
120
hours
135
hours

ENGLISH
16
Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put motorcycle
on the stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the three clamp screws
1 of the top triple clamp and turn steering stem bolt 2clockwise until
there is no more play. Don’t tighten the steering stem bolt all the way,
otherwise the bearings will be damaged. With a plastic hammer, lightly rap
on the triple clamp to release tension. Retighten the three clamp screws to
20 Nm.
 WARNING 
IFTHE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-
CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.
! CAUTION !
IFYOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE
BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
The steering head bearings should be regreased at least once a year
(i.e. Motorex Long Therm 2000).
 WARNING 
ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH AN ASTERISK * REQUIRE
SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER WHERE YOUR
MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF.
! CAUTION !
–When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings,
carburetor, electric connectors, etc.
–W
HEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT
THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK
–ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR
LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
–D
ONOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING
LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
–Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned.
–Dispose of Oils, fatty matters, filters, fuels, washing detergents, etc. properly.
–Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter of used oil contamina-
tes 1,000,000 liters of water.
MAINTENANCE WORK ON CHASSIS AND ENGINE
2
1

ENGLISH
17
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs 1a few turns in order to relieve excess pressure from the inside of
the fork. To do this, place the motorcycle on a stand with the front wheel
lifted off the ground.
! CAUTION !
EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF
YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE
HAVING THE SEALS REPLACED.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 2are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind
the dust-protection bellows. If this dirt is not removed, the oil sealing rings
located behind it may start to leak.
Use a screwdriver to lift the dust-protection bellows out of the outer tubes
and slide them downward.
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with silicone spray or engine oil. Then, push dust-pro-
tection bellows into the outer tubes by hand.
 WARNING 
NOSILICONE OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD
CONSIDERABLY REDUCE THE TIRE'SROAD GRIP AND THE BRAKING EFFECT OF THE FRONT
BRAKE.
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar in the position that is the most convenient for you. The upper tri-
ple clamp 3includes 2 bores arranged at a distance of 15 mm (0.6 in) from
one another. The bores at the handlebar support 4are offset from the cen-
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws 5of the handlebar clamps and screws 6
of the handlebar support. Position handlebar support, and tighten screws 6
to 40 Nm. Mount handlebar and handlebar clamps, and tighten screws 5
to 20 Nm. The gap between the handlebar support and handlebar clamps
should be the same size in the front and in the rear.
 WARNING 
THE SCREWS 6MUST BE SECURED WITH LOCTITE 243.
2
1
3
4
5
6
15 mm
3,5 mm

ENGLISH
18
Changing the spring preloading of the shock absorber
The spring preload can be changed by turning the adjusting ring 1. For this
purpose, you should dismount the shock absorber and clean it thoroughly.
NOTE:
–Before changing the spring preload note down the basic setting, e.g.
how many threads are visible above the adjusting ring.
–One rotation of the adjusting ring 1changes the spring pretension by
approximately 1.75 mm (0.07 in).
Loosen the clamping screw 2and use the hook wrench contained in the
vehicle tool set to turn the adjusting ring as desired. Turning it counter-
clockwise will reduce the preload, turning it clockwise will increase the
preload. After readjusting the clamping screw 2, tighten it to 8 Nm (6 ft.lb)
Checking chain tension
Support the motorcycle on the center stand or side stand, respectively.
Switch transmission to neutral. Push the chain upwards from the end of the
chain sliding component until the upper part of the chain is tensioned.
Now, the distance between chain and swingarm should be 0 mm.
The upper part of the chain must be tight. Correct chain tension, if
necessary!
 WARNING 
–IFTHE CHAIN IS TOO TIGHT THE SECONDARY TRANSMISSION COMPONENTS (CHAIN,
SPROCKETS, BEARINGS OF THE TRANSMISSION AND OF THE REAR WHEEL) WILL BE PUT
UNDER ADDITIONAL STRAIN THAT CAN, IN ADDITION TO PREMATURE WEAR, ALSO
CAUSE CHAIN BREAKAGE.
–I
FTHE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND BLOCK
THE REAR WHEEL OR DAMAGE THE ENGINE.
–I
NBOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
Loosen collar nut 3, loosen lock nuts 4, and turn right and left adjusting
screws 5equally far. Tighten lock nuts.
Before tightening the collar nut, verify that the chain adjusters 6are sitting
close to the adjusting screws and that the rear wheel has been aligned with
the front wheel.
Tighten collar nut 3to 80 Nm (60 ft.lb).

WARNING

–IFYOU DON’THAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU
HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI-
BLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR
MOTORCYCLE.
–T
IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE
MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.
NOTE:
The large adjusting range of the chain adjusters (32mm) allows you to use
different secondary ratios in combination with the same chain length. The
chain adjusters 6can be rotated by 180°.
!
CAUTION
!
ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED.
Chain maintenance
For long chain life, good maintenance is very important. The chain should
be cleaned in fireproof solvent regularly and afterwards treated with hot
grease or chain spray (Motorex Chainlube 622).
 WARNING 
NOLUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS, OTHER-
WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE
STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.
! CAUTION !
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK
CLIP MUST POINT IN RUNNING DIRECTION.
Also check sprockets and chain guides for wear, and replace if necessary.
✓
4
3
4
1
2
5
5
6
0 mm
A

ENGLISH
19
General information about KTM disc brakes
BRAKE CALIPERS:
If the front brake caliper is removed, the screws must be secured with Loc-
tite 243 when mounted and tightened to 20 Nm.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not neces-
sary to top up the brake fluid. If the brake fluid level drops below the mini-
mum level either the brake system has a leak or the brake pads are comple-
tely worn. In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake system with ”Motorex Brake Fluid DOT 5.1”, one of the
best brake fluids currently available. We recommend that you continue to
use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake
fluid. DOT 4 shown on the lid means minimum standard. However, you
should replace it as soon as possible by DOT 5.1.
 WARNING 
HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IFYOU WASH YOUR
MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.
BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCKETS MAY FORM IN
"OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO
FAIL.
BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face 1of the brake pads decreases. At their thinnest point A, the brake
discs must not be more than 0.40 mm (0.016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location Boutside
the contact face. Check wear in several locations.
 WARNING 
–B
RAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.40 MM (0.016 IN) CONSTI-
TUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS
THEY REACH THE WEAR LIMIT.
–HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER.
Adjusting free travel of the hand brake lever
Free travel of the hand brake lever may be readjusted by using the adjust-
ment screw 2. In this way, the position of the point of pressure (i.e. the
resistance you feel on the hand brake lever when the brake pads are
pressed against the brake disc) can be adjusted for any hand size.
! CAUTION !
ATTHE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN). ONLY
THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY
THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IFTHIS FREE TRAVEL IS NOT
PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL
BRAKE MAY FAIL DUE TO OVERHEATING.
min. 3 mm
DOT
5.1
DOT
5
✓✕
A
B
1
2